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Doosan Solar 220LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
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Doosan Solar 220LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Solar 220LL
Shop Manual
2023-7134AE
Serial Number 1001 and Up
June 2004
2023-7134AE
Serial Number 1001 and Up
June 2004
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Description
Doosan Solar 220LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
DESCRIPTION:
Doosan Solar 220LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Solar 220LL
Shop Manual
2023-7134AE
Serial Number 1001 and Up
June 2004
2023-7134AE
Serial Number 1001 and Up
June 2004
GENERAL SAFETY ESSENTIALS ACCESSORY APPLICATIONS:
- This excavator has been primarily designed for moving logs. For use other object handling devices, contact DOOSAN for proper installation and application. Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no sideloading.
- Do not use the machine for activities for which it was not intended. Do not use the grapple for lifting work (other than logs). Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.
LIFTING CAPACITY RATING CONFIGURATION:
- Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration.
- Loads must be balanced and supported evenly. Use tag lines to keep the load steady if wind conditions and large surface area are a problem.
- Work crew hand signals, individual tasks and safe procedures should all be universally understood before the lift is made.
TABLE OF CONTENTS:
Doosan Solar 220LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Publication Request for Proposed Revision............................................................................... 7 Safety.................................................................................................................. 9 Track Excavator Safety S0102010..................................................................................... 11 To the Operator of a DOOSAN Daewoo Excavator.................................................................... 13 Learn Signal Words Used With Safety Alert Symbol............................................................ 14 General Safety Essentials....................................................................................... 15 Accessory Applications...................................................................................... 15 Lifting Capacity Rating Configuration....................................................................... 15 Location of Safety Labels....................................................................................... 15 Summary of Safety Precautions for Lifting in Digging Mode....................................................... 16 Unauthorized Modifications.................................................................................. 16 Work Site Precautions........................................................................................... 17 Attachment Precautions...................................................................................... 17 Avoid High Voltage Cables................................................................................... 17 Be Aware of Height Obstacles................................................................................ 17 Use Care on Loose Support................................................................................... 17 Use Solid Support Blocking.................................................................................. 17 Overhangs Are Dangerous..................................................................................... 18 Sloping Terrain Requires Caution............................................................................ 18 Stay Alert for People Moving through the Work Area.......................................................... 18 Be Aware of and Conform to Local Regulations................................................................ 18 Operation....................................................................................................... 19 Operate While Seated at the Operator's Station ONLY......................................................... 19 Before Starting the Engine.................................................................................. 19 Never Use Ether Starting Aids............................................................................... 20 Mounting and Dismounting.................................................................................... 20 Observe General Safety Rules................................................................................ 20 Engine Ventilation.......................................................................................... 20 Asbestos Dust Hazard Prevention............................................................................. 21 Take Time to Provide Good Visibility........................................................................ 21 Fuel, Oil and Hydraulic Fluid Fire Hazards.................................................................. 22 Boost Starting or Charging Engine Batteries................................................................. 22 Travel Controls May Produce Reversed Operations............................................................. 23 Keep "Pinch Point" Areas Clear - Use Caution in Reverse and Swing........................................... 23 Travel Precautions.......................................................................................... 23 Operate Carefully on Snow and Ice and in Very Cold Temperatures............................................. 23 Parking Machine............................................................................................. 24 Shutdown Control Functions.................................................................................. 24 Additional Operational Comments............................................................................. 24 Equipment....................................................................................................... 25 Rough Operation May Require Use of Certified Safety Equipment............................................... 25 Install Additional Safety Equipment If Conditions Require................................................... 25 Movement Alarms............................................................................................. 25 Seat Belts Must Be Used at All Times........................................................................ 26 Window Glass Breaking Tool.................................................................................. 26 Keep a Fire Extinguisher at Hand............................................................................ 26 Maintain Standard Safety Equipment in Good Condition........................................................ 26 Safety - critical Parts Must Be Replaced Periodically....................................................... 27 Hydraulic Cylinder Seals Require Periodic Replacement....................................................... 27 High-pressure Hydraulic Lines Can Store a Great Deal of Energy.............................................. 27 The Operator's Cabin and Turntable Deck Must Be Kept Clean.................................................. 27 Clothing and Personal Protective Items...................................................................... 27 Breathing Masks, Ear Protection May Be Required............................................................. 28 Battery Electrolyte and Explosive Gases Can Be Lethal....................................................... 28 Disconnect Batteries for Electrical Service Before Electrical Welding....................................... 28 Use Low Heat Portable Lighting.............................................................................. 28 Maintenance..................................................................................................... 29 Use Warning Tag Control Lockout Procedures During Service................................................... 29 Do not Run the Engine If Repairs or Work Is Being Performed Alone........................................... 29 Always Use Adequate Equipment Supports and Blocking......................................................... 29 Warning for Counterweight and Front Attachment Removal...................................................... 29 Do not Work on Hot Engines or Hot Cooling or Hydraulic Systems.............................................. 30 Cool Down Is Required Before Radiator or Reservoir Checks................................................... 30 Precautions with High-pressure Line, Tubes and Hoses........................................................ 31 Obtain immediate medical attention if pressurized oil pierces the skin...................................... 31 Use Correct Replacement Fasteners Tightened to Proper Torque................................................ 32 Dispose of All Petroleum Based Oils and Fluids Properly..................................................... 32 Track Tension Adjustments Require Caution................................................................... 32 Do not attempt repairs you do not understand. There is no disgrace in asking for help....................... 32 All Welding Must Be Performed By Qualified Welder........................................................... 32 Cylinders................................................................................................... 33 Hydraulic Cylinders, Pins and Bushings...................................................................... 33 Shipping and Transportation..................................................................................... 34 Obey State and Local Over-the-Road Regulations.............................................................. 34 Lifting With Sling.............................................................................................. 34 Specifications.......................................................................................................... 35 Specifications for Solar 220LL S0205010............................................................................. 37 General Description............................................................................................. 39 General Dimensions.............................................................................................. 42 Dimensions and Working Range.................................................................................... 44 General Specifications.......................................................................................... 45 Engine Performance Curve........................................................................................ 46 Performance Tests............................................................................................... 47 Excavator Performance Standards................................................................................. 48 Test Conditions............................................................................................. 48 Travel Speed and Travel Motor Balance (Steering Deviation) Tests............................................ 48 Speed Test.............................................................................................. 48 Travel Deviation........................................................................................ 49 Swing Speed Test........................................................................................ 50 Swing Force Test........................................................................................ 50 Cylinder Performance Tests.................................................................................. 51 Boom Cylinders Test..................................................................................... 51 Stick Cylinder Test..................................................................................... 51 Heel Cylinder Test...................................................................................... 51 Hydraulic Cylinder Natural Drop Test.................................................................... 51 Travel Motor Jack-up Test............................................................................... 51 General Maintenance..................................................................................................... 53 General Maintenance Procedures S0302000............................................................................. 55 Welding Precautions and Guidelines.............................................................................. 57 Hydraulic System General Precautions.......................................................................... 58 Maintenance Service and Repair Procedure........................................................................ 59 General Precautions......................................................................................... 59 Hydraulic System Cleanliness and Oil Leaks...................................................................... 60 Maintenance Precautions for Hydraulic System Service........................................................ 60 Oil Leakage Precautions..................................................................................... 60 Cleaning and Inspection......................................................................................... 61 General Guidelines.......................................................................................... 61 Bearing inspection.......................................................................................... 62 Normal Bearing.......................................................................................... 63 Bent Cage............................................................................................... 63 Galling................................................................................................. 63 Abrasive Step Wear...................................................................................... 64 Etching................................................................................................. 64 Misalignment............................................................................................ 64 Indentations............................................................................................ 64 Fatigue Spalling........................................................................................ 65 Brinelling.............................................................................................. 65 Cage Wear............................................................................................... 65 Abrasive Roller Wear.................................................................................... 65 Cracked Inner Race...................................................................................... 66 Smears.................................................................................................. 66 Frettage................................................................................................ 66 Heat Discoloration...................................................................................... 67 Stain Discoloration..................................................................................... 67 Standard Torques S0309000........................................................................................... 69 Torque Values for Standard Metric Fasteners..................................................................... 71 Torque Values for Standard U.S. Fasteners....................................................................... 72 Type 8 Phosphate Coated Hardware................................................................................ 74 Torque Values for Hose Clamps................................................................................... 75 Torque Values for Split Flanges................................................................................. 76 Torque Wrench Extension Tools................................................................................... 77 Torque Multiplication....................................................................................... 77 Other Uses for Torque Wrench Extension Tools................................................................ 78 Tightening Torque Specifications (Metric)................................................................... 78 I. "Loctite" Fastener Adhesives......................................................................... 79 II. "Loctite" Pipe Thread Sealant....................................................................... 79 III. "Loctite" gasket/flange sealer..................................................................... 79 IV. "Loctite" retaining compounds....................................................................... 80 V. "Loctite" Adhesives.................................................................................. 80 Upper Structure......................................................................................................... 81 Cabin S0402000...................................................................................................... 83 Removal......................................................................................................... 85 Installation.................................................................................................... 87 Window and Gasket Replacement................................................................................... 90 Falling Object Protective Structures (FOPS)..................................................................... 91 Counterweight S0403000.............................................................................................. 93 General......................................................................................................... 95 Removal......................................................................................................... 97 Installation.................................................................................................... 99 Fuel Tank S0405050..................................................................................................101 General Description.............................................................................................103 Parts List..................................................................................................104 Specifications..............................................................................................105 Removal.........................................................................................................106 Installation....................................................................................................110 Start-up Procedures.............................................................................................112 Fuel Transfer Pump S0405500.........................................................................................113 General Description.............................................................................................115 Theory of Operation.........................................................................................115 Troubleshooting.................................................................................................116 Replacement of Rotor and Vane...................................................................................116 Replacement of Rear Cover.......................................................................................117 Replacement of Armature.........................................................................................118 Swing Bearing S0407000..............................................................................................119 Swing Bearing Maintenance.......................................................................................121 Operating Recommendation....................................................................................121 Measuring Swing Bearing Axial Play..........................................................................121 Measuring Bearing Lateral Play..............................................................................121 Swing Bearing Basic Operation...............................................................................122 Rebuilding Swing Bearing....................................................................................122 Swing Reduction Gearbox S0408010....................................................................................125 General Description.............................................................................................127 Theory of Operation.........................................................................................127 Parts List..................................................................................................128 Specifications..............................................................................................129 Special Tools and Materials.....................................................................................130 Special Tools...............................................................................................130 Drive Shaft Front Bearing Jig...........................................................................130 Oil Seal Insert Jig.....................................................................................130 Spring Pin Insert Jig...................................................................................130 Troubleshooting, Testing and Adjustment.........................................................................131 Removal.........................................................................................................132 Disassembly.....................................................................................................133 Cleaning and Inspection (Wear Limits and Tolerances)............................................................138 Reassembly......................................................................................................139 Installation....................................................................................................148 Lower Structure and Chassis.............................................................................................149 Track Assembly S0505040.............................................................................................151 General Description.............................................................................................153 Specifications..............................................................................................153 Track Link..............................................................................................153 Track Shoe..............................................................................................153 Lower Rollers...........................................................................................153 Lower Rollers...........................................................................................153 Front Idler.............................................................................................153 Track Tension...................................................................................................154 Cleaning and Inspection (Wear Limits and Tolerances)............................................................156 Track Shoes and Links...........................................................................................159 Parts List..................................................................................................159 Track Removal...............................................................................................160 Track Installation..........................................................................................161 Front Idler Roller..............................................................................................162 Parts List..................................................................................................162 Front Idler Roller Disassembly..............................................................................163 Front Idler Roller Reassembly...............................................................................165 Upper and Lower Roller..........................................................................................166 Parts List..................................................................................................166 Lower Roller Removal........................................................................................167 Lower Roller Disassembly....................................................................................167 Lower Roller Reassembly.....................................................................................168 Lower Roller Installation...................................................................................169 Upper Roller Removal........................................................................................170 Upper Roller Disassembly....................................................................................170 Upper Roller Reassembly.....................................................................................170 Track Spring and Track Adjusting Cylinder.......................................................................171 Parts List..................................................................................................171 Engine and Drive Train..................................................................................................173 Air Conditioner S0605010............................................................................................175 General Description.............................................................................................177 Refrigerant Circulation.........................................................................................178 Control Panel...................................................................................................180 Control Specifications..........................................................................................181 Temperature Level Control and Display...........................................................................182 Air Discharge According to Path Selection.......................................................................183 Vent........................................................................................................183 Foot........................................................................................................184 Defroster...................................................................................................185 Air-conditioning System Circuit Diagram.........................................................................186 Troubleshooting.................................................................................................188 Refrigerant Pressure Check..................................................................................188 Weight of R134a Gas Used In Machines............................................................................191 Refrigerant System Repairs......................................................................................193 Refrigerant Safe Handling Procedures........................................................................193 Repair and Replacement Procedure............................................................................194 Refrigerant Recovery........................................................................................196 Vacuuming Refrigerant System................................................................................196 Leakage Check...............................................................................................198 Refrigerant Charging........................................................................................199 Inspecting System for Leakage...............................................................................200 Drive Coupling (Main Pump) S0609000.................................................................................203 Drive Coupling..................................................................................................205 Special Tools...................................................................................................206 Kawasaki / Tong Myung Pump Tool.............................................................................206 Uchida Pump Tool............................................................................................209 Drive Coupling Installation.....................................................................................211 Installation Procedure......................................................................................216 Hydraulics..............................................................................................................217 Hydraulic System Troubleshooting, Testing and Adjustment S0702070...................................................219 Hydraulic System - General Notes................................................................................222 Operation of Working Components.................................................................................223 Boom Operating Circuit......................................................................................223 Boom Up Circuit.............................................................................................223 Boom Down Circuit...........................................................................................223 Arm Operating Circuit.......................................................................................224 Arm Crowd Circuit...........................................................................................224 Arm Dump Circuit............................................................................................225 Bucket Operating Circuit....................................................................................225 Bucket Crowd Circuit........................................................................................225 Bucket Dump Circuit.........................................................................................225 Swing Operating Circuit.....................................................................................226 Right Swing Operating Circuit...............................................................................226 Left Swing Operating Circuit................................................................................226 Swing Relief Valve and Makeup Valve.........................................................................226 Travel Operating Circuit....................................................................................226 Forward Travel Circuit......................................................................................227 Reverse Travel Circuit......................................................................................227 Procedural Troubleshooting Baseline Recommendations.............................................................228 Initial Checks and Tests to Establish Operating Condition of the Excavator..................................228 Triage Summary..........................................................................................228 Pilot Pressure..................................................................................................229 Adjustment and Testing......................................................................................229 Power Mode Valve................................................................................................230 Current Signal and Hydraulic Pressure Adjustments...........................................................230 Boom/Swing Priority Valve.......................................................................................231 Control Valve Pressure and Current Adjustments..............................................................231 Dip Switch Setting (Export / Domestic)..................................................................232 Pressure Up Valve...............................................................................................233 Checks and Adjustments......................................................................................233 Pump Input Power Control........................................................................................235 Pump Regulator Adjustment...................................................................................235 Flow Meter and Flow Meter Kit Installation and Testing..........................................................238 Installation and Testing Procedure..........................................................................238 Swing System Troubleshooting....................................................................................240 Precautions/Initial Checks..................................................................................240 Swing Relief Valve Checking and Adjustment..................................................................240 Troubleshooting - Swing Gearbox.................................................................................242 Troubleshooting - Hydraulic Problems............................................................................243 Troubleshooting - Control Valve.................................................................................245 Troubleshooting - Travel Control Valve..........................................................................246 Troubleshooting - Joystick Control Valve........................................................................246 Accumulator S0703000................................................................................................249 General Description.............................................................................................251 Specifications..............................................................................................252 Accumulator Charging............................................................................................255 Charging the Accumulator with Nitrogen......................................................................255 Center Joint (Swivel) S0704010......................................................................................257 General Description.............................................................................................259 Parts List..................................................................................................260 Type 1..................................................................................................260 Type 2..................................................................................................262 Troubleshooting, Testing and Adjustment.........................................................................264 Inspection..................................................................................................264 Testing.....................................................................................................264 Disassembly.....................................................................................................265 Reassembly......................................................................................................266 Swing Motor S0707210................................................................................................267 General Description.............................................................................................269 Theory of Operation.........................................................................................269 Swing Motor Anticavitation Makeup Valve.....................................................................270 Relief Valve................................................................................................271 Swing Brake Operation.......................................................................................271 Parts List..................................................................................................274 Specifications..............................................................................................275 Special Tools...................................................................................................276 Disassembly.....................................................................................................277 Cleaning and Inspection (Wear Limits and Tolerances)............................................................284 Service Standards for Replacing Worn Parts..................................................................285 Reassembly......................................................................................................286 Travel Motor (With Gearbox) (GM35VL) S0707330.......................................................................293 General Description.............................................................................................295 Theory of Operation.........................................................................................295 Hydraulic Motor Operation...............................................................................296 Reduction Gearbox Operation.............................................................................301 Travel Motor Parts List.....................................................................................302 Travel Reduction Gearbox Parts List.........................................................................304 Specifications..............................................................................................306 Name Plate Identification...............................................................................306 Specifications..........................................................................................307 Recommended Bolt, Plug Sizes and Torques................................................................307 Troubleshooting, Testing and Adjustment.........................................................................308 General Notice..............................................................................................308 Troubleshooting.............................................................................................308 Disassembly.....................................................................................................312 Preparation for Travel Motor and Reduction Gear Disassembly.................................................312 Travel Motor Rear Flange Disassembly........................................................................314 Spool Disassembly.......................................................................................314 Check Valve Disassembly.................................................................................314 Two Speed Switching Valve Disassembly...................................................................315 Disassembly of Internal Parts (SRV).....................................................................315 Relief Valve Disassembly................................................................................316 Travel Motor Internal Parts Disassembly.....................................................................318 Parking Brake Parts Disassembly.........................................................................318 Motor Internal Parts Disassembly........................................................................319 Cylinder Block Disassembly..............................................................................320 Input Gear Disassembly..................................................................................320 Spur Gear Disassembly...................................................................................321 Hold Flange Disassembly.................................................................................322 Ball Bearing, RV Gear Assembly, and Pin Disassembly.....................................................323 Spindle Disassembly.....................................................................................324 Bearing (149) Disassembly...............................................................................325 Cleaning and Inspection (Wear Limits and Tolerances)............................................................326 General Inspection..........................................................................................326 Gear Oil....................................................................................................326 General Notice..............................................................................................326 Tightening Torque List......................................................................................327 Wear Limits.................................................................................................327 Reassembly......................................................................................................329 General Instructions for Reassembly.........................................................................329 Travel Motor Rear Flange Reassembly.........................................................................329 Check Valve Reassembly..................................................................................329 Spool Reassembly........................................................................................329 Two Speed Switching Valve Reassembly....................................................................330 Internal Parts Reassembly (SRV).........................................................................331 Relief Valve Reassembly.................................................................................331 Travel Reduction Gear Reassembly............................................................................334 Hub Reassembly..........................................................................................334 Spindle Reassembly......................................................................................334 Hub and Spindle Reassembly..............................................................................335 RV Gear Reassembly......................................................................................335 Piston Assembly (161 and 162) Reassembly................................................................339 Cylinder Block Internal Parts Reassembly................................................................339 Motor Reassembly........................................................................................340 Gear Holding Flange Gap Measurement and Adjustment..........................................................341 RV Gear Gap Measurement and Adjustment......................................................................342 Travel Motor and Reduction Gear Reassembly..................................................................343 Reduction Gear Cover Reassembly.............................................................................345 Travel Motor (With Gearbox) (TM40VC) S0707331K......................................................................347 General Description.............................................................................................349 Theory of Operation.........................................................................................349 Hydraulic Motor Operation...............................................................................350 Reduction Gearbox Operation.............................................................................355 Travel Motor Parts List.....................................................................................356 Travel Reduction Gearbox Parts List.........................................................................358 Specifications..............................................................................................360 Name Plate Identification...............................................................................360 Specifications..........................................................................................361 Recommended Bolt, Plug Sizes and Torques................................................................361 Troubleshooting, Testing and Adjustment.........................................................................362 General Notice..............................................................................................362 Troubleshooting.............................................................................................362 Disassembly.....................................................................................................366 Preparation for Travel Motor and Reduction Gear Disassembly.................................................366 Travel Motor Rear Flange Disassembly........................................................................368 Spool Disassembly.......................................................................................368 Check Valve Disassembly.................................................................................368 Two Speed Switching Valve Disassembly...................................................................369 Disassembly of Internal Parts (SRV).....................................................................369 Relief Valve Disassembly................................................................................370 Travel Motor Internal Parts Disassembly.....................................................................372 Parking Brake Parts Disassembly.........................................................................372 Motor Internal Parts Disassembly........................................................................373 Cylinder Block Disassembly..............................................................................374 Input Gear Disassembly..................................................................................374 Spur Gear Disassembly...................................................................................375 Hold Flange Disassembly.................................................................................376 Ball Bearing, RV Gear Assembly, and Pin Disassembly.....................................................377 Spindle Disassembly.....................................................................................378 Bearing (149) Disassembly...............................................................................379 Cleaning and Inspection (Wear Limits and Tolerances)............................................................380 General Inspection..........................................................................................380 Gear Oil....................................................................................................380 General Notice..............................................................................................380 Tightening Torque List......................................................................................381 Wear Limits.................................................................................................381 Reassembly......................................................................................................383 General Instructions for Reassembly.........................................................................383 Travel Motor Rear Flange Reassembly.........................................................................383 Check Valve Reassembly..................................................................................383 Spool Reassembly........................................................................................383 Two Speed Switching Valve Reassembly....................................................................384 Internal Parts Reassembly (SRV).........................................................................385 Relief Valve Reassembly.................................................................................385 Travel Reduction Gear Reassembly............................................................................388 Hub Reassembly..........................................................................................388 Spindle Reassembly......................................................................................388 Hub and Spindle Reassembly..............................................................................389 RV Gear Reassembly......................................................................................389 Piston Assembly (161 and 162) Reassembly................................................................393 Cylinder Block Internal Parts Reassembly................................................................393 Motor Reassembly........................................................................................394 Gear Holding Flange Gap Measurement and Adjustment..........................................................395 RV Gear Gap Measurement and Adjustment......................................................................396 Travel Motor and Reduction Gear Reassembly..................................................................397 Reduction Gear Cover Reassembly.............................................................................399 Grapple Rotate Motor S0707400.......................................................................................401 General Description.............................................................................................403 General Notes...............................................................................................403 Torqmotor™ Features.........................................................................................404 Parts List..................................................................................................406 Special Tools and Materials.....................................................................................407 Special Tools...............................................................................................407 Tools and Materials Required for Servicing..................................................................408 Torque Chart................................................................................................409 Troubleshooting, Testing and Adjustment.........................................................................410 Preliminary Checks..........................................................................................410 Hydraulic Components........................................................................................410 Disassembly and Inspection (Preparation Before Disassembly).................................................411 Disassembly.....................................................................................................413 Reassembly......................................................................................................422 One Piece Stator Reassembly.................................................................................434 Two Piece Stator Reassembly.................................................................................435 Start-up Procedures.............................................................................................437 Hydraulic Fluid.............................................................................................437 Main Pump (With Regulator) S0708320.................................................................................439 General Description.............................................................................................441 Gear (Pilot) Pump...........................................................................................443 Relief Valve................................................................................................443 Pump Regulator Description..................................................................................444 Horsepower Control..........................................................................................444 Power Shift Control.........................................................................................444 Negative Oil Discharge (Pump Bypass) Control................................................................444 Pump Regulator Operation....................................................................................445 Pump Output Decrease........................................................................................447 Pump Discharge Decrease.....................................................................................447 Pump Discharge Increase.....................................................................................447 Horsepower Control..........................................................................................447 Overload Protection.........................................................................................448 Regulator Adjustment........................................................................................448 Pump Input Power Control Adjustment.........................................................................449 Electric Proportional Reducing Valve....................................................................449 Parts List..................................................................................................450 Main Pump...............................................................................................450 Pump Regulator..........................................................................................452 Specifications..............................................................................................454 Models: SOLAR 220LC-V, 220LL, AND 250LC-V...............................................................454 Model: SOLAR 225LC-V....................................................................................454 Model: SOLAR 225NLC-V...................................................................................454 Model: SOLAR 255LC-V....................................................................................455 Hydraulic Pump Performance Characteristics..................................................................456 Main Pump Pressure/Flow Output (Models: SOLAR 220LC-V (S/N 1001 thru 2018), 220LL (S/N 1001 thru .......456 Main Pump Pressure/Flow Output (Models: SOLAR 220LC-V (S/N 2019 and Up), 220LL (S/N 1084 and Up),.......456 Main Pump Pressure/Flow Output (Model: SOLAR 225LC-V)...................................................456 Main Pump Pressure/Flow Output (Models: SOLAR 225NLC-V).................................................456 Main Pump Pressure/Flow Output (Model: SOLAR 255LC-V)...................................................457 Troubleshooting, Testing and Adjustment.........................................................................463 Main Pump...................................................................................................463 Disassembly.....................................................................................................464 General Disassembly.........................................................................................464 Main Pump Disassembly.......................................................................................465 Pump Regulator Disassembly..................................................................................467 Cleaning and Inspection (Wear Limits and Tolerances)............................................................471 Service Standards for Replacing Worn Parts..................................................................472 Reassembly......................................................................................................473 Pump Regulator Reassembly...................................................................................473 Main Pump Reassembly........................................................................................477 Main Control Valve S0709400.........................................................................................481 Control Valve Operation.........................................................................................484 Swing Priority Circuit......................................................................................484 Arm Priority Circuit........................................................................................485 Bucket (Junction) Circuit...................................................................................486 Straight Traveling Circuit..................................................................................487 Plunger Replacement.........................................................................................489 Main Relief Valve...........................................................................................490 Overload Relief Valve.......................................................................................491 Arm Load Holding Valve......................................................................................493 Boom Load Holding Valve.....................................................................................496 Arm Regeneration............................................................................................498 Boom Regeneration...........................................................................................500 Foot Relief Valve...........................................................................................501 Parts List..................................................................................................502 Main Plunger Element....................................................................................502 Main Relief Valve.......................................................................................503 Overload Relief Valve...................................................................................504 Bucket Unity Check......................................................................................505 Boom Load Holding Valve.................................................................................506 Boom Unity Check........................................................................................506 Arm Regeneration Valve..................................................................................507 Foot Relief Valve.......................................................................................507 Arm Priority Valve [Ap Valve]...........................................................................507 Check Valve [Tr, Am-2]..................................................................................508 Check Valve [Opt, Bkt, Bm-1, Bm-2]......................................................................508 Check Valve.............................................................................................508 Check Valve.............................................................................................509 Cap.....................................................................................................509 Check Valve [Tl]........................................................................................509 Check Valve [Sw]........................................................................................510 Check Valve [Am-1]......................................................................................510 Straight Travel Selector Valve..........................................................................510 Swing Priority Valve [Sp Valve].........................................................................511 Center Bypass Valve [Cb Valve]..........................................................................511 Arm Load Holding Valve..................................................................................512 Specifications..............................................................................................512 Control Valve Drawing and Hydraulic Circuit.....................................................................513 Disassembly and Reassembly......................................................................................518 General Disassembly.........................................................................................518 General Reassembly..........................................................................................518 Main Plunger Element - Disassembly and Assembly.............................................................519 Tool........................................................................................................519 Main Relief Valve...........................................................................................522 Main Relief Valve Adjustment................................................................................523 Main Relief Valve - Reassembly..........................................................................523 High-pressure Adjustment................................................................................524 Low-pressure Adjustment.................................................................................524 Overload Relief Valve.......................................................................................525 Arm Load Holding Valve......................................................................................527 Check Valve Main Body...................................................................................527 Cover Assembly..........................................................................................528 Boom Load Holding Valve.....................................................................................530 Arm Regeneration Valve......................................................................................532 Bucket Unity Check..........................................................................................533 Foot Relief Valve...........................................................................................534 Center Bypass Valve (CB Valve)..............................................................................535 Boom Parallel Switch Valve..................................................................................536 Tool........................................................................................................536 Swing Priority Valve........................................................................................538 Pilot Switch Element....................................................................................539 Boom Unity Check Valve......................................................................................540 Straight Travel Selector Valve..............................................................................541 Check Valve - Locations.....................................................................................542 Check Valve.................................................................................................543 A: Check Valve (Main Relief Valve, TS)..................................................................543 B: Check Valve (P2).....................................................................................543 C: Check Valve [TR, AM-2]...............................................................................544 D: Check Valve [OPT, BKT, BM-1, BM-2]...................................................................544 E: Check Valve [TL].....................................................................................545 F: Check Valve [SW].....................................................................................546 G: Check Valve [AM-1]...................................................................................547 Pilot Control Valve (Work Lever / Joystick) S0709450................................................................549 General Description.............................................................................................551 Theory of Operation.........................................................................................551 Neutral Mode............................................................................................551 Control Mode............................................................................................551 Parts List..................................................................................................552 Specifications..............................................................................................553 Torques.................................................................................................553 Performance.............................................................................................554 Hydraulic Specifications....................................................................................554 Special Tools...................................................................................................555 Disassembly.....................................................................................................556 Reassembly......................................................................................................561 Travel Control Valve S0709800.......................................................................................567 General Description.............................................................................................569 Theory of Operation.........................................................................................569 Pressure Reducing Valve.................................................................................569 Damping Device of Operation.............................................................................570 Operating Levers in Neutral Position....................................................................571 When levers are operated and direction is quickly reversed..............................................571 Parts List..................................................................................................572 Specifications..............................................................................................573 Torque Table................................................................................................573 Special Tools and Materials.....................................................................................574 Special Tools...............................................................................................574 Special Jig 1 [For Separating Bushing (223)]............................................................574 Special JIg 2 [For Assembly of Retainer Ring (221)].....................................................575 Troubleshooting, Testing and Adjustment.........................................................................576 Disassembly.....................................................................................................577 Cleaning and Inspection (Wear Limits and Tolerances)............................................................584 Reassembly......................................................................................................585 Hydraulic Schematic (Solar 220LL) S0792020..........................................................................595 General Description.............................................................................................597 Solar 220LL.....................................................................................................598 General Notes...............................................................................................600 Electrical System.......................................................................................................601 Electrical System S0802035..........................................................................................603 Troubleshooting - Electrical System.............................................................................606 Wiring Harness Illustrations....................................................................................607 Overview........................................................................................................607 Electric Wire Color.........................................................................................607 Electric Supply System..........................................................................................608 Engine Starting Circuit.........................................................................................609 Operation During Start Process..............................................................................609 Operation After Start Process...............................................................................610 Operation of the Start Circuit (2) - Immediately After Start............................................610 Engine Preheating System........................................................................................611 Engine Stop System..............................................................................................612 Operation In Engine Running Mode............................................................................612 Operation In Engine Stop Mode...............................................................................614 Charging System.................................................................................................616 Monitoring System...............................................................................................617 Instrument Panel................................................................................................618 Function Check..................................................................................................620 Monitoring System Schematic.................................................................................620 Operation.......................................................................................................622 Instruments.................................................................................................622 Mode Selector Switch............................................................................................624 Indicator Lights................................................................................................625 Initial Operation...............................................................................................626 Electronic Hydraulic Control System (EPOS- V)...................................................................628 Power Mode Control..............................................................................................630 Operation...................................................................................................631 1. Power Mode III.......................................................................................631 2. Power Mode II........................................................................................632 3. Power Mode I.........................................................................................633 Power Mode Control - Circuit Diagram............................................................................635 Work Mode Control...............................................................................................636 Operation...................................................................................................637 1. Leveling Mode........................................................................................637 2. Digging Mode.........................................................................................637 3. Trenching Mode.......................................................................................637 Work Mode Control - Circuit Diagram.............................................................................638 Engine Control System...........................................................................................639 Engine Control Motor............................................................................................640 Engine Control Dial.............................................................................................641 Engine Control Circuit Diagram..................................................................................642 Automatic Deceleration Control (Auto Idle Control)..............................................................643 Engine Overheat Protection System...............................................................................644 Power Boost Mode................................................................................................645 Operation...................................................................................................645 Power Boost Control - Circuit Diagram.......................................................................646 Automatic Travel Speed Control..................................................................................647 Automatic Travel Speed Control - Circuit Diagram............................................................648 Engine Control Device - Adjustment..............................................................................649 Self-diagnostic Function........................................................................................652 EPOS-V Controller...........................................................................................652 Engine Throttle Controller......................................................................................656 Electrical Schematic (Solar 220LL) S0892020.........................................................................657 General Description.............................................................................................659 Solar 220LL.....................................................................................................660 Attachments.............................................................................................................663 Boom and Stick S0902020.............................................................................................665 Front Attachment Specifications.................................................................................667 Pin Specifications..........................................................................................667 Size and Weight Specifications..............................................................................667 Front Attachment - Removal and Installation.....................................................................668 Stick Removal Procedure.....................................................................................668 Boom Removal Procedure......................................................................................670 Installation....................................................................................................671 Stick Installation Procedure................................................................................671 Boom Installation Procedure.................................................................................671 Start-up Procedures.............................................................................................672
DOOSAN SOLAR 220LL EXCAVATOR LOG LOADER SHOP MANUAL – PDF DOWNLOAD:
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
R.D
